Integrated Coolant Filler Neck Assembly for Overflow Reservoir Packaging
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Solution Overview
Problem
Conventional coolant overflow systems in vehicles result in increased size and manufacturing costs due to the remote location of overflow and makeup reservoirs, necessitating additional tubes or hoses, which also increase weight.
Innovation Solution
A coolant filler neck assembly with an integrated coolant overflow reservoir that includes a cylinder housing with internal fluid conduits for overflow management, eliminating the need for external connections and reducing overall size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a remote overflow and makeup reservoir is used, then coolant overflow functionality is achieved, but the overall size and weight of the system increase
Solution Approach 1:
The patent combines the overflow reservoir and makeup reservoir functions into the filler neck assembly itself, eliminating the need for a separate remote reservoir. The filler neck serves dual purposes as both a coolant filling point and an overflow containment chamber, thereby reducing overall system weight while maintaining coolant overflow functionality.
2Reliability
If a remote overflow and makeup reservoir is used, then coolant overflow functionality is achieved, but the overall size of the system increases
Solution Approach 1:
The overflow reservoir is integrated within the filler neck assembly structure, combining multiple functions into a single compact unit. This eliminates the need for separate remote reservoirs and connecting hoses, significantly reducing the overall system size and footprint in the vehicle engine bay.
3Reliability
If external tubes or hoses are used to connect the reservoir, then coolant overflow functionality is achieved, but manufacturing costs increase
Solution Approach 1:
The filler neck assembly is designed as an integrated unit where the overflow reservoir, filler opening, and internal fluid conduits are formed as one piece or pre-assembled module. This eliminates the need for separate external tubes and hoses, reducing the number of parts, assembly steps, and manufacturing costs.
4Reliability
If external tubes or hoses are used to connect the reservoir, then coolant overflow functionality is achieved, but the system weight increases
Solution Approach 1:
By integrating the overflow reservoir within the filler neck assembly, the patent eliminates the weight of external connecting tubes and hoses. The filler neck assembly itself serves as the containment structure, removing the need for additional fluid-carrying components and reducing overall system weight.
Data Source
AI summary
A coolant filler neck assembly for a pressurized cooling system. The coolant filler neck includes a cylinder housing defining a non-pressurized coolant overflow reservoir; an upper cap member attached to an upper region of the cylinder housing, the upper cap member including an overflow inlet port member arranged internally in the coolant overflow reservoir and a filler pipe member in fluidic communication with the overflow inlet port member and the pressurized cooling system; a first fluid overflow tube member arranged internally in the coolant overflow reservoir to extend in a longitudinal direction though a first region of the non-pressurized coolant overflow reservoir to direct overflow liquid coolant to the non-pressurized coolant overflow reservoir; and a second fluid overflow tube member arranged internally in the coolant overflow reservoir to extend in a longitudinal direction though a second region of the non-pressurized coolant overflow reservoir to direct the overflow liquid coolant from the non-pressurized coolant overflow reservoir to the ambient environment.